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Wearable sweat biosensors offer compelling opportunities for improved personal health monitoring and non-invasive measurements of key biomarkers. Inexpensive device fabrication methods are necessary for scalable manufacturing of portable, disposable, and flexible sweat sensors. Furthermore, real-time sweat assessment must be analyzed to validate measurement reliability at various sweating rates. Here, we demonstrate a “smart bandage” microfluidic platform for cortisol detection and continuous glucose monitoring integrated with a synthetic skin. The low-cost, laser-cut microfluidic device is composed of an adhesive-based microchannel and solution-processed electrochemical sensors fabricated from inkjet-printed graphene and silver solutions. An antibody-derived cortisol sensor achieved a limit of detection of 10 pM and included a low-voltage electrowetting valve, validating the microfluidic sensor design under typical physiological conditions. To understand effects of perspiration rate on sensor performance, a synthetic skin was developed using soft lithography to mimic human sweat pores and sweating rates. The enzymatic glucose sensor exhibited a range of 0.2 to 1.0 mM, a limit of detection of 10 μM, and reproducible response curves at flow rates of 2.0 μL min −1 and higher when integrated with the synthetic skin, validating its relevance for human health monitoring. These results demonstrate the potential of using printed microfluidic sweat sensors as a low-cost, real-time, multi-diagnostic device for human health monitoring.
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This content will become publicly available on March 18, 2026
Advanced Microfluidic‐Based Wearable Electrochemical Sensors for Continuous Biochemical Monitoring
Abstract Microfluidic‐based wearable electrochemical sensors represent a transformative approach to non‐invasive, real‐time health monitoring through continuous biochemical analysis of body fluids such as sweat, saliva, and interstitial fluid. These systems offer significant potential for personalized healthcare and disease management by enabling real‐time detection of key biomarkers. However, challenges remain in optimizing microfluidic channel design, ensuring consistent biofluid collection, balancing high‐resolution fabrication with scalability, integrating flexible biocompatible materials, and establishing standardized validation protocols. This review explores advancements in microfluidic design, fabrication techniques, and integrated electrochemical sensors that have improved sensitivity, selectivity, and durability. Conventional photolithography, 3D printing, and laser‐based fabrication methods are compared, highlighting their mechanisms, advantages, and trade‐offs in microfluidic channel production. The application section summarizes strategies to overcome variability in biofluid composition, sensor drift, and user adaptability through innovative solutions such as hybrid material integration, self‐powered systems, and AI‐assisted data analysis. By analyzing recent breakthroughs, this paper outlines critical pathways for expanding wearable sensor technologies and achieving seamless operation in diverse real‐world settings, paving the way for a new era of digital health.
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- Award ID(s):
- 2203806
- PAR ID:
- 10598420
- Publisher / Repository:
- Adv. Opt. Materials
- Date Published:
- Journal Name:
- Advanced Electronic Materials
- ISSN:
- 2199-160X
- Subject(s) / Keyword(s):
- TFT transistors
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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